Motor 1.6 DOCH

Engine Mechanical
System
[1.6 DOHC] ....
GENERAL ENGINE BLOCK
SPECIFICATION ........................................... EMA -2 COMPONENTS ............................................ EMA -56
TROUBLE SHOOTING ................................. EMA -11 DISASSEMBLY ............................................. EMA -58
SPECIAL TOOLS .......................................... EMA -14 INSPECTION ................................................ EMA -60
REASSEMBLY .............................................. EMA -71
TIMING SYSTEM
COMPONENTS ............................................ EMA -16 COOLING SYSTEM
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REMOVAL ..................................................... EMA -17 COMPONENTS ............................................ EMA -77
INSPECTION ................................................ EMA -21 ENGINE COOLANT REFILLING AND BLEEDING
INSTALLATION ............................................. EMA -22 ........................................................... EMA -79
REMOVAL ..................................................... EMA -81
CYLINDER HEAD ASSEMABLY INSPECTION ................................................ EMA -85
COMPONENTS ............................................ EMA -27 INSTALLATION ............................................. EMA -86
REMOVAL ..................................................... EMA -29
DISASSEMBLY ............................................. EMA -33 LUBRICATION SYSTEM
INSPECTION ................................................ EMA -34 COMPONENTS ............................................ EMA -87
REPLACEMENT ........................................... EMA -38 OIL AND FILTER ........................................... EMA -89
REASSEMBLY .............................................. EMA -39 REMOVAL ..................................................... EMA -91
INSTALLATION ............................................. EMA -40 DISASSEMBLY ............................................. EMA -91
INSPECTION ................................................ EMA -92
ENGINE AND TRANSAXLE ASSEMABLY REASSEMBLY .............................................. EMA -93
REMOVAL ..................................................... EMA -46 INSTALLATION ............................................. EMA -94
INSTALLATION ............................................. EMA -55
INTAKE AND EXHAUST SYSTEM
COMPONENTS ............................................ EMA - 96
EMA -2 ENGINE MECHANICAL SYSTEM [1.6 DOHC]
GENERAL
SPECIFICATIONS EB50426A
Description Specifications Limit

General
Type In-line, Double Overhead Camshaft
Number of cylinder 4
Bore 76.Smm (3.0118in)
Stroke 87mm (3.42S2in.)
Total displacement 1S99cc (97.S4cu.in.)
Compression ratio 10.1
Firing order 1 - 3 - 4 - 2
Valve timing
Intake valve
Opens (BTDC) so
Closes (ABDC) 3S 0
Exhaust valve
Opens (BBDC) 43°
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Closes (ATDC) so
Valve overlap 10°
Cylinder head
Flatness of cylinder surface MAX. 0.03mm (0.0012in.) 0.1mm (0.0039in.)
Flatness of mainfold mounting 0.1Smm (O.OOS9in.) 0.2mm (0.008in.)
surface
Oversize rework dimension
of valve seat hole
Intake
0.3mm (0.012in.) O.S. 30.7- 30.721mm (1.2087- 1.209Sin.)
0.6mm (0.024in.) O.S. 31.0 - 31.021 mm (1.220S - 1.2213in.)
Exhaust
0.3mm (0.012in.) O.S. 27.3- 27.321 mm (1.0748 - 1.07S6in.)
0.6mm (0.024in.) O.S. 27.6- 27.621mm (1.0866- 1.0874in.)
Oversize rework dimensions
of valve
Guide hole
O.OSmm (0.002in.) O.S. 11.0S - 11.068mm (0.43S - 0.43S7in.)
0.2Smm (0.01 Oin.) O.S. 11.2S - 11.268mm (0.443 - 0.4436in.)
O.SOmm (0.020in.) O.S. 11.SO- 11.S18mm (0.4S3 - 0.4S3Sin.)
Camshaft
Camlobe height
Intake 43.4484mm (1.7106in.) 42.9S84mm (1.6909in.)
Exhaust 43.8489mm (1.7263in.) 43.3489mm (1.7066in.)
Journal O.D 027mm (1.0630in.)
Bearing oil clearance 0.03S - 0.072mm (0.0014 - 0.0028in.)
End play 0.1 - 0.2mm (0.004 - 0.008in.)
GENERAL EMA-3

Valve
Valve length
Intake 91.8mm (3.61 02in.}
Exhaust 92.4mm (3.6339in.}
Stem 0.0.
Intake 5.955 - 5.97mm (0.2344 - 0.2350in.}
Exhaust 5.935 - 5.95mm (0.2337 - 0.2343in.}
Face angle thickness of valve
head (Magin}
Intake 1.1 mm (0.0433in.} 0.8mm (0.031 in.}
Exhaust 1.3mm (0.0512in.} 1.0mm (0.039in.}
Valve stem to stem guide
clearance
Intake 0.03 - 0.06mm (0.0012 - 0.0024in.} 0.1 Omm (0.0039in.}
Exhaust 0.05 - 0.08mm (0.0020 - 0.0031 in.} 0.15mm (0.0059in.}
Valve guide
Installed dimension 0.0
Intake 12.8mm (0.504in.}
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Exhaust 12.8mm (0.504in.}
Service oversize 0.05, 0.25, 0.50mm
(0.002, 0.01 0, 0.020in.} oversize
Valve seat
Width of seat contact
Intake 0.8 - 1.2mm (0.031 - 0.047in.)
Exhaust 1.3 - 1.7mm (0.051 - 0.066in.}
Seat angle 45°
Oversize 0.3, 0.6mm (0.012, 0.024in.} oversize
Valve spring
Free length 44.00mm (1.7323in.}
Load 21.6kg/35mm (47.61b/1.3780in.}
45.1 kg/27.2mm (99.41b/1.709in.)
Squarences 1.5° or less
Cylinder block
Cylinder bore 76.50 - 76.63mm (3.0118 - 3.0130in.}
Out-of-round and taper of Less than 0.01 mm (0.0004in.}
cylinder bore
Clearance with piston 0.02 - 0.04mm (0.0008 - 0.0016in.}
Piston
0.0 76.47- 76.50mm (3.010- 3.012in.}
Service size 0.25mm
(0.01 Oin.} oversize
Piston ring
Side clearance
No. 1 0.04 - 0.085mm (0.0015 - 0.0033in.} 0.1 mm (0.004in.}
No. 2 0.04- 0.085mm (0.0015- 0.0033in.) 0.1 mm (0.004in.}
End gap
No. 1 0.15 - 0.30mm (0.0059 - 0.0118in.) 1.0mm (0.039in.)
No. 2 0.30- 0.45mm (0.0118- 0.0177in.) 1.0mm (0.039in.}
Oil ring side rail 0.2 - 0.7mm (0.0078 - 0.0275in.) 1.0mm (0.039in.)
Service 0.25mm (0.01 Oin.} oversize
EMA-4 ENGINE MECHANICAL SYSTEM [1.6 DOHC]

Connecting rod
Bend 0.05mm (0.0020in.) or less
Twist 0.1 mm (0.0039in.) or less
Connecting rod big and to 0.1 00 - 0.250mm (0.0039 - 0.0098in.) 0.4mm (0.0157in.)
crankshaft side clearance
Connecton rod bearing oil 0.018 - 0.036mm (0.0007 - 0.0014in.)
clearance
Undersize 0.25, 0.50, 0.75mm
(0.01 0, 0.020, 0.030in.)
Crankshaft
Pin O.D. 45mm (1.nin.)
Journal O.D. 50mm (1.97in.)
Bend 0.03mm (0.0012in.) or less
Out-of-round, taper of journal 0.005mm (0.0002in.) or less
and pin
End play 0.05- 0.175mm (0.0019- 0.0068in.)
Undersize rework dimension
of pin
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0.25mm (0.010in.) 44.725- 44.74mm (1.7608- 1.7614in.)
0.50mm (0.020in.) 44.475 - 44.49mm (1.7509 - 1.9485in.)
0.75mm (0.030in.) 44.225 - 44.24mm (1.7511 - 1.9386in.)
Undersize rework dimension
of journal
0.25mm (0.01 Oin.) 49.727- 49.742mm (1.95n- 1.9583in.)
0.50mm (0.020in.) 49.477 - 49.492mm (1.9479 - 1.9485in.)
0.75mm (0.030in.) 49.227 - 49.242mm (1.9380 - 1.9386in.)
Flywheel
Runout 0.1mm (0.0039in.) 0.13mm (0.0051 in.)
Oil pump
Clearance between outer
circumference and front case 0.12 - 0.18nm (0.0047 - 0.0070in.)
(body clearance)
Front case tip clearance 0.025 - 0.069mm (0.001 - 0.0027in.)
Side clearance
Inner gear 0.04 - 0.085mm (0.0016 - 0.0033in.)
Outer gear 0.06 - 0.11 mm (0.0024 - 0.0043in.)
Engine oil pressure
Engine at idle [Oil temperature is 147kPa (1.5kg/cm2 , 21.33psi)
90 to 100°F (194 to 215°F)]
Relief spring
Free height 46.6mm (1.8346in.)
Load 6.1 kg at 40.1 mm (13.421b/1.578in.)
Water-cooled, pressurized, forced
Cooling method
circulation with electrical fan
Coolant
Quantity 6 liter
Radiator
Type Pressurized corrugated in type
GENERAL EMA-5

Radiator cap
Main valve opening pressure 81.4 - 108kpa (11.8 - 15.6psi,
0.83 - 1.1 kg/cm2)
Vacuum valve opening pressure -6.86kpa (-1.00, -0.07kg/cm 2 or less)
Coolant pump Centrifugal type tmpeller
Thermostat
Type Wax pellet type with jiggle valve
Valve opening temperature 82°C (180°F)
Full-opening temperature 95°C (203°F)
Engine coolant temperature
Type Heat-sensitive thermistor type
Resistance 2.31 - 2.59kQ at 20°C (68°F)
146.9 - 147.3Q at 11 ooc (230°F)
Air cleaner
Type Dry type
Element Unwoven cloth type
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Exhaust pipe
Muffler Expansion resonance type
Suspension system Rubber hangers
~NOTE
0.0 = Outer Diameter
I.D = Inner Diameter
O.S = Oversize Diameter
U.S = Undersize Diameter
TIGHTENING TORQUE
Item Nm kgf.cm lbf.ft

Cylinder Block
Front engine support bracket bolt and nut 45- 55 450- 550 33 - 41
Engine support bracket bolt and nut 45-55 450- 550 33 - 41
Oil pressure switch 13- 15 130 - 150 10 - 11
Cylinder Head
Cylinder head bolt 30+(90°)+Release all 300+(90°)+Release 22+(90°)+Release all
bolts+30+(90°) all bolts+300+(90°) bolts+22+(90°)
Intake manifold bolt or nuts 15- 20 150- 200 11 - 15
Exhaust manifold nut 30- 35 300- 350 22- 26
Cylinder head cover bolt 8- 10 80- 100 6- 7
Camshaft bearing cap bolt 12- 14 120 - 140 9- 10
Main Moving System
Connecting rod cap nut 32- 35 320- 350 24-26
Crankshaft bearing cap bolt 55- 60 550- 600 41 - 44
Fly wheel M!T bolt 120 - 130 1200 - 1300 89- 96
Drive plate AfT bolt 120 - 130 1200- 1300 89- 96
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Timing System
Crankshaft pulley bolt 140 - 150 1400- 1500 103-111
Camshaft sprocket bolt 80 - 100 800- 1000 59- 74
Timing belt tensioner bolt 20- 27 200- 270 15- 20
Timing belt idle bolt 43- 55 430- 550 32 - 41
Timing belt cover bolt 8 - 10 80- 100 6- 7
Front case bolt 20- 27 200- 270 15- 20
GENERAL EMA-7
Item Nm kgf.cm lbf.ft

Engine Mounting
Right mounting insulator (large) nut 90- 110 900- 1100 66 - 81
Right mounting insulator (small) nut 45- 60 450- 650 33- 44
Right mounting bracket to engine 50- 65 500- 650 37 -48
nuts and bolts
Transmission mount insulator nut 90 - 110 900- 1100 66- 81
Transmission insulator bracket to side 40- 50 400- 500 30 -36
member bolts
Rear roll stopper insulator nut 50- 65 500- 650 37-48
Rear roll stopper bracket sub frame bolts 40-50 400- 500 30- 36
Front roll stopper insulator nut 50-65 500- 650 36-48
Front roll stopper bracket to sub frame bolts 40-50 400- 500 30- 36
Oil filter 12- 16 120 - 160 9 - 12
Oil pan bolt 10- 12 100- 120 7- 9
Oil pan drain plug 40-45 400- 450 30- 33
Oil screen 15- 22 150- 220 11 - 16
Alternator support bolt and nut 20-25 200- 250 15 - 18
Alternator lock bolt 12- 15 120 - 150 9- 11
Alternator brace mounting bolt 20-27 200- 270 15- 20
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Coolant pump pulley 8 - 10 80- 100 6- 7
Coolant pump bolt 12- 15 120 - 150 9- 11
Coolant temperature sensor 25- 30 250- 300 18- 22
Coolant inlet fitting bolt 17- 20 170- 200 13- 14
Thermostat housing bolt 15- 20 150- 200 11 - 14
Intake and Exhaust system
Air cleaner body mounting bolts 8- 10 80- 100 6- 7
Resonator mounting bolts 4- 6 40- 60 3- 4
Intake manifold to cylinder head nuts and bolts 15- 20 150- 200 11 - 14
Surgetank stay to cylinder head nuts and bolts 15- 20 180- 250 13 - 18
Throttle body to surgetank nuts 18- 25 150- 200 11 - 14
Exhaust manifold to cylinder head nuts 30-35 300- 350 22-26
Exhaust manifold cover to exhaust 15- 20 150- 200 11 - 14
manifold bolts
Oxygen sensor to exhaust manifold 50-60 500- 600 37- 44
Front exhaust pipe to exhaust manifold nuts 30-40 300- 400 22- 30
Front exhaust pipe bracket bolts 30-40 300- 400 22- 30
Front exhaust pipe to catalytic converter bolts 40-60 400- 600 30-44
SERVICE STANDARD
Standard value
Antifreeze Maxture ratio of anti-freeze in coolant
ETHYLENE GLYCOL BASE FOR ALUMINUM 50%
COMPRESSION c. while cranking the engine, measure the compres-

sion pressure.
~NOTE
If the there is lack of power, excessive oil consump- ~NOTE
tion or poor fuel economy, measure the compression Always use a fully charged battery to obtain engine
pressure. speed of 250 rpm or more.
1. Warm up and stop engine. d. Repeat steps (a) through (c) for each cylinder.
Allow the engine to warm up to normal operating tem-
perature.
~NOTE
2. Remove ignition coils (See EE group - ignition) This measurement must be done in as short a time as
possible.
3. Remove spark plugs.
Using a 16mm plug wrench, remove the 4 spark plugs. Compression pressure :
1,500kPa (15.3kgf/cm2, 218psi)
4. Check cylinder compression pressure Minimum pressure :
a. Insert a compression gauge into the spark plug 1OOOkPa (1 0.2kgf/cm2 , 145psi)
hole. Difference between each cylinder :
1OOkPa (1.0kgf/cm2, 15psi) or less
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e. If the cylinder compression in 1 or more cylinders
is low, pour a small amount of engine oil into the
cylinder through the spark plug hole and repeat
steps (a) through (c) for cylinders with low com-
pression.
• If adding oil helps the compression, it is likely
that the piston rings and/or cylinder bore are
worn or damaged.
• If pressure stays low, a valve may be stick-
ing or seating is improper, or there may be
leakage past the gasket.
5. Reinstall spark plugs.
6. Install ignition coils. (see EE- ignition)
KDPC001B
b. Fully open the throttle.

GENERAL EMA-9
TIMING BELT TENSION ADJUSTMENT 7. Turn the crankshaft pulley, and align its groove with
timing mark "T" of the timing belt cover.
1. Remove the engine cover.
2. Remove RH front wheel.
3. Remove the 4bolts (B) and timing belt upper cover (A).
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KCDC002C ECKD106A
4. Remove the alternator belt. 8. Remove the crankshaft pulley (A).
5. Remove the air compressure belt.
6. Remove the power steering belt.
KDDC007B
9. Remove the timing belt lower cover.
10. Temperarily loosen tensioner pulley.

11. Timing belt tension adjusting 14. Install the crankshaft pulley (A).
1) Rotate crankshaft in regular direction (clock wise

view from front) through angle equivalent to two
teeth (18°) of camshaft sprocket.
2) Give tension to timing belt rotating tensioner in

arrow direction tool and set timing belt not to give
slack to tension side.
3) Tightening tensioner bolt.
Tightening torque
Tensioner bolt :
43- 55Nm (430- 550kgf.cm, 32- 401bf.ft)
4) Then recheck the belt tension.

Verify that when the tensioner and the tension
side of the timing belt are pushed in horizontally
with a moderate force [approx. 49N (111b)], the
timing belt cog end is aprox.
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1/2 of the tensioner mounting bolt head radius KDDC0078
(across flats) away from the bolt head center.

15. Install the driver belts.
16. Install the timing belt upper cover (A) with 4bolts (B).
EDKD108A
12. Turn the crankshaft two turns in the operating direc-

tion (clockwise) and realign crankshaft sprocket and KCDC002C
camshaft sprocket timing mark.

17. Install RH front wheel.
13. Install the timing belt lower cover.
18. Install engine cover with 4bolts.
GENERAL EMA -11
TROUBLESHOOTING E531F7E2
Symption Suspect area Remedy (See page)

Engine misfire with abnormal Loose or improperly installed Repair or replace the flywheel
internal lower engine noises. engine flywheel. as required.
Worn piston rings Inspect the cylinder for a loss
(Oil consumption may or may not of compression.
cause the engine to misfire.) Repair or replace as required.
Replace the crankshaft and bearings
Worn crankshaft thrust bearings
as required
Engine misfire with abnormal Stuck valves.
Repair or replace as required
valve train noise. (Carbon buidup on the valve stem)
Excessive worn or mis-aligned Replace the timing chain and
timing chain sprocket as required.
Worn camshaft lobes. Replace the camshaft and HLA.
Engine misfire with coolant • Faulty cylinder head gasket and/or
• Inspect the cylinder head and
consumption cranking or other damage to
engine block for damage to
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the cylinder head and engine
the coolant passages and/or a
block cooling system.
faulty head gasket.
• Coolant consumprion may or may
• Repair or replace as required.
not cause the engine to overheat.
Engine misfire with excessive Worn valves, guides and/or valve
Repair or replace as required.
oil consumption stem oil seals.
Worn piston rings. • Inspect the cylinder for a loss
(Oil consumption may or may not of compression.
cause the engine to misfire) • Repair or replace as required.
Engine noise on start-up, but • Drain the oil.
Incorrect oil viscosity
only lasting a few seconds. • Install the correct viscosity oil.
• Inspect the thrust bearing
Worn crankshaft thrust bearing. and crankshaft.
Upper engine noise, regardless Low oil pressure Repair or repalce as required.
of engine speed.
Broken valve spring. Replace the valve spring.
Worn or dirty valve lifters. Replace the valve lifters.
Stetched or broken timing chain and/or
Replace the timing chain and sprockets.
damaged sprocket teeth.
Worn timing chain tensioner, if Replace the timing chain tensioner
applicable. as required.
• Inspect the camshaft lobes.
Worn camshaft lobes. • Replace the timing camshaft and
valve lifters as required.
Inspect the valves and valve guides,
Worn valve guides or valve stems.
then repair as required.
Stuck valves. (Carbon on the valve
Inspect the valves and valve guides,
stem or valve seat may cause the
then repair as required.
valve to stay open.

Lower engine noise, regardless Low oli pressure. Repair or required.
of engine speed
Loose or damaged flywheel. Repair or replace the flywheel.
• Inspect the oil pan.
Damaged oil pan, contacting the
• Inspect the oil pump screen.
oil pump screen.
Oil pump screen loose, damaged • Inspect the oil pump screen.
or restircted. • Repair or replace as required.
• Inspect the piston, piston pin
Excessive piston-to-cylinder bore
and cylinder bore.
clearance.
• Repair as required.
• Inspect the piston, piston pin
Excessive piston pin-to-clearance and the connecting rod.
Inspect the following components
and repair as required.
Excessive connecting rod bearing • The connecting rod bearings.
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rod clearance • The connecting rods.
• The crankshaft.
• The crankshaft journal.
Inspect the following components,
Excessive crankshaft bearing clearance
• The crankshaft bearing.
• The crankshaft journals.
• Verify the piston pins and
Incorrect piston, piston pin and connecting rods are installed
connecting rod installation correctly.
• Repair as required.
Engine noise under load Low oil pressure Repair or replace as required.
Inspect the following components
and repair as required :
Excessive connecting rod bearing
• The connecting rod bearings.
clearance
• The connecting rods.
• The crankshaft
Inspect the following components,
Excessive crankshaft bearing clearance • The crankshaft bearings.
• The crankshaft journals.
• The cylinder block crankshaft
GENERAL EMA -13

Engine will not crank-crankkshaft 1. Remove spark plugs and
will not rotate check for fluid.
Hydraulically cylinder
2. Inspect for broken head gasket.
• Coolant/antifreeze in cylinder.
• Oil in cylinder.
3. Inspect for cracked engine black
or cylinder head.
• Fuel in cylinder
4. Inspect for a sticking fuel injector
and/or leaking fuel regulator.
Broken timing chain and/or timing chain 1. Inspect timing chain and gears.
and/or timing chain gears. 2. Repair as required.
Material cylinder 1. Inspect cylinder for damaged
• Broken valve components and/or foreign
• Piston material materials.
• Foreign material 2. Repair or replace as required.
1. Inspect crankshaft and connecting
Seized crankshaft or connecting
rod bearing.
rod bearings.
2. Repair as required.
1. Inspect connecing rods.
Bent or broken connecting rod.
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1. Inspect crankshaft.
Broken crankshaft
SPECIAL TOOLS EBA76AE3
Tool (Number and name) Illustration Use

Crankshaft front oil seal installer Installation of the front oil seal
(09214-32000)
EDKA010A
Crankshaft front oil seal guide Installation of the front oil seal
(09214-321 00)
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EDKA010B
Camshaft oil seal installer Installation of the camshaft oil seal

(09221-21 000)
EDDA005B
Valve guide installer Removal and installation of the valve guide

(09221-3F1 00 NB)
ECKA010B
Valve stem oil seal installer Installation of the valve stem oil seal
(09222-22001)
ECKA010A
Valve spring compressor Removal and installation of the intake

& adaptor or exhaust valve
(09222-28000, 09222-281 00)
EDDA005C
GENERAL EMA -15
Tool (Number and name) Illustration Use

Crankshaft rear oil seal installer 1. Installation of the engine rear oil seal
(09231-21 000) 2. Installation of the crankshaft rear oil seal
EDDA005F
Water temperature sensor Removal and installation of the water

scoket wrench temperature sensor
(09221-25100)
EDKD101B
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TIMING SYSTEM
TIMING BELT
COMPONENT E2EOEDOB
Cylinder head cover
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Timing belt upper cover Camshaft sprocket
80-100
(800 -1000,
59 -74)
TORQUE : Nm (kgf•cm, lbf•ft)

EDKD100A
TIMING SYSTEM EMA -17
REMOVAL EBB6EFFB 2) Remove the bolt (B), 3nuts (C) and engine mount
bracket (A).
Engine removal is not required for this procedure.
2. Remove RH front wheel.
3. Remove 2bolts (B) and RH side cover (A).
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EDKD101A
5. Temporarily loosen the water pump pulley bolts.
KXDSE16A
4. Remove the engine mount bracket.
1) Set the jack to the engine oil pan.
ECKD104B
6. Remove alternator belt.(see EE group- alternator)
7. Remove air compressor belt.(see HA group - com-

pressor)
8. Remove power steering belt.(see ST group - power

steering pump)
ECKD102A
9. Remove 4bolts and water pump pulley.

~NOTE
Place wooden block between the jack and engine oil
pan.
10. Remove the 4bolts (B) and timing belt upper cover (A). 12. Remove the crankshaft pulley bolt and crankshaft pul-
ley (A).
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KCDC002C
ECKD107A
11. Turn the crankshaft pulley, and align its groove with
timing mark ''T'of the timing belt cover. 13. Remove the crankshaft flange (A).
ECKD108A
ECKD106A
14. Remove the 5bolts and timing belt lower cover. 15. Remove the timing belt tensioner (A) and timing belt.
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ECKD10BB EDKD102B
EDKD102A
~NOTE
If the timing belt is reused, make an arrow indicating
the turning direction to make sure that the belt is rein-
stalled in the same direction as before.
16. Remove the bolt (B) and timing belt idler (A). 18. Remove the cylinder head cover.
1) Remove the spark plug cable.
2) Remove the accelerator cable (A) from the cylin-

der head cover.
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EDKD103A
17. Remove the crankshaft sprocket (A).
ECKD111A
3) Remove the PCV(Positive Crankcase ventilation)

hose (A) and breather hose (B).
ECKD110A
ECKD112A
4) Remove the 10bolts (B) and cylinder head cover INSPECTION EEEEC21B
(A).
SPROCKETS, TENSIONER, IDLER
1. Check the camshaft sprocket, crankshaft sprocket,

tensioner pulley, and idler pulley for abnormal wear,
cracks, or damage. Replace as necessary.
2. Inspect the tensioner pulley and the idler pulley for

easy and smooth rotation and check for play or noise.
Replace as necessary.
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EDK0104A
19. Remove camshaft sprocket.
1) Hold the hexagonal head wrench (A) portion of

the camshaft with a wrench (B), and remove the
EDKD106A
bolt and camshaft sprocket (C).
3. Replace the pulley if there is a grease leak from its
bearing.
TIMING BELT
1. Check the belt for oil or dust deposits.

Replace, if necessary.
Small deposits should be wiped away with a dry cloth
or paper. Do not clean with solvent.
2. When the engine is overhauled or belt tension ad-

justed, check the belt carefully. If any of the following
flaws are evident, replace the belt.
[YJ) NOTE
• Do not bend, twist or turn the timing belt inside
out.
• Do not allow the timing belt to come into contact
with oil, water and stem.
EDKD105A
& CAUTION
Be careful not to damage the cylinder head and
valve lifter with the wrench.
INSTALLATION E70917F7 2. Install cylinder head cover
1. Install the camshaft sprocket and tighten the bolt to 1) Install cylinder head cover (A)and 1Obolts (B).
the specified torque.
1) Temporarily install the camshaft sprocket bolt.
2) Hold the hexagonal head wrench (A) portion of

the camshaft with a wrench (B), and tighten the
camshaft sprocket (C) bolt.
Tightening torque
Camshaft sprocket bolt :
80- 100Nm (800- 1000kgf.cm, 59- 741bf.ft)
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EOK0104A
2) Install the PCV hose (A) and breather hose (B).
B
EDKD105A
ECK0112A
3) Install the accelerator cable (A) from the cylinder 4. Align the timing marks of the camshaft sprocket (A)
head cover. and crankshaft sprocket (B) with the No. 1 piston
placed at top dead center and its compression stroke.
Timing mark
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ECKD111A
ECDDOOSF
4) Install the spark plug cable.
3. Install the crankshaft sprocket (A).
EDKD107A
ECKD110A
5. Install the idler pulley (A) and tighten the bolt (B) to 7. Belt so as not give slack at each center of shaft. Do
the specified torque. as following procedures when installing timing belt.
Crankshaft sprocket (A) ~ Idler pulley (B) ~
Tightening torque Camshaft sprocket (C)~ timing belt tensioner (D).
Idler pulley bolt :
43- 55Nm (430- 550kgf.cm, 32- 401bf.ft)
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EDKD109A
EDKD103A 8. Temporarily fasten tensioner pulley to add force at

belt.
6. Temporarily install the timing belt tensioner(A).
9. Timing belt tension adjusting
1) Rotate crankshaft in regular direction (clock wise

view from front) through angle equivalant to two
eeth (18" ) of camshaft sprocket.
2) Give tension to timing belt by rotating tensioner

in arrow driection with tool and set timing belt not
to give slack to tension side
3) Tightening tensioner bolt.
Tightening torque
Tensioner bolt :
20 - 27Nm (200 - 270kgf.cm, 15 - 201bf.ft)
KDPC008E
4) Then recheck the belt tension. 12. Install the flange and crankshaft pulley (A).
Verify that when the tensioner and the tension Make sure that crankshaft sprocket pin fits the small
side of the timing belt are pushed in horizon- hole in the pulley.
tally with a moderate force [approx. 49N(11lb)],
the timing belt cog end approx. 1/2 of the ten- Tightening torque
sioner mounting bolt head radius (across flats) Crankshaft pulley bolt :
away from the bolt head center. 140 - 150Nm (1400 - 1500kgf.cm, 103 - 111lbf.ft)
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EDKD108A
ECKD107A
10. Turn the crankshaft two turns in the operating direc-

tion (clockwise) and realign crankshaft sprocket and 13. Install the timing belt upper cover (A) with 4bolts (B).
camshaft sprocket timing mark.
11. Install the timing belt lower cover (A) with 5 bolts.
Tightening torque
Timing belt cover bolt :
8- 10Nm (80 -100kg.cm, 6- 71bf.ft)
KCDC002C
14. Install the coolant pump pulley with 4bolts.
15. Install power steering belt. (see ST group - power

steering pump)
16. Install air compressor bolt. (see HA group - compres-

ECKD108B sor)
17. Install alternator belt. (see EE group - alternator)
18. Install the engine mount bracket
1) Install engine mount bracket (A) with 3nuts (C)

and bolt (B).
Tightening torque
17mm nut: 60 -80Nm (600- 800kgf.cm 44- 591bf.ft)
14mm nut : 50 -65Nm (500 - 650kgf.cm 37 - 481bf.ft)
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EDKD101A
19. Install RH side cover (A) with 2bolts (B).
KXDSE16A
20. Install RH front wheel.
21. Install engine cover with 4bolts.

CYLINDER HEAD ASSEMBLY EMA -27
CYLINDER HEAD
ASSEMBLY
COMPONENTS EA1CD010
8- 10 (80 -100,6- 7.4)
Cylinder head cover
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Cylinder head
Cylinder block
TORQUE : Nm (kgf.cm, lbf.ft)

EDKD110A
c-:1, .---HLA
Retainer"""~
lock ~Retainer
f?J
\9)
Valve spring Timing chain
VStemseal
Spring:.:~ ~~
~--=-------7 Chain sprocket
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Camshaft
sprocket
TORQUE : Nm (kgf.cm, lbf·ft)

EDKD111A
REMOVAL EF75DE2E 3. Drain the engine coolant(see page EMA-79).

Remove the radiator cap to speed draining.
Engine removal is not required for this procedure.
4. Remove the intake air hose and air cleaner assembly.
& CAUTION 1) Remove the heat shield (A).
• Use fender covers to avoid damaging painted
surfaces.
• To avoid damaging the cylinder head, wait un-
til the engine coolant temperature drops be-
low normal temperature before removing it.
• When handling a metal gasket, take care not
to fold the gasket or damage the contact sur-
face of the gasket.
• To avoid damage, unplug the wiring connec-
tors carefully while holding the connector
portion.
@]NOTE
• Mark all wiring and hoses to avoid misconnec-
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tion.
• Inspect the timing belt before removing the cylin- A
der head.
• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center.(see page EMA-9).
ECKD600A
1. Disconnect the negative terminal from the battery.

2) Disconnect the breather hose from air cleaner
hose.
3) Remove the intake air hose and air cleaner as-

sembly.
5. Remove the upper radiator hose(A) and lower radiator

hose(B).
ECKD201B

EDKD112B
6. Remove the heater hoses (A). 3) TPS(Throttle Position Sensor) connector (A).
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KCPC003F EDKD112A
7. Remove the engine wire harness connectors and wire 4) ISA(Idle Speed Actuator) connector.
harness clamps from the cylinder head and the intake
manifold. 5) CMP(Camshaft Position Sensor) connector.
1) ECT(Engine Coolant Temperature) sensor con-
6) Four fuel injector connectors (A).
nector.
2) Ignition coil connector (A). 7) Knock sensor connector (B).
EDKD112C EDKD113B
8) Front heated oxygen sensor connector (A). 9. Remove the PCSV hose (A).
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ECKD206A EDKD113C
9) PCSV(Purge Control Solenoid Valve) connector. 10. Remove the brake booster vacuum hose (A).
8. Remove the fuel inlet hose (A) from delivery pipe.
KCPC0038
EDKD113A
11. Remove the accelerator cable by loosening the lock-
nut, then slip the cable end out of the throttle linkage.
12. Remove the power steering pump.(see ST group -

power steering pump).
13. Remove the spark plug cable.
14. Remove the PCV hose.
15. Remove the cylinder head cover( see page EMA-21 ).
16. Remove the timing belt(see page EMA-17).

17. Remove the exhaust manifold(see page EMA-97). 21. Remove the cylinder head bolts, then remove the
cylinder head.
18. Remove the intake manifold.(see page EMA-96).
1) Using 8mm hexagon wrench, uniformly loosen
19. Remove the camshaft sprocket.(see page EMA-21 ). and remove the 10 cylinder head bolts, in several
passes, in the sequence shown. Remove the 10
20. Remove the camshaft bearing caps (A) and cylinder head bolts and plate washers.
camshafts (8).
3 5 10 8 2
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7 9 6 4
EDK0115A
EDKD114A
& CAUTION
Head warpage or cracking could result from re-
moving bolts in an incorrect order.
2) Lift the cylinder head from the dowels on the

cylinder block and replace the cylinder head on
wooden blocks on a bench.
& CAUTION
Be careful not to damage the contact surfaces of
the cylinder head and cylinder block.
DISASSEMBLY E3BFFF4D 4) Remove the valve.
5) Remove the using needle-nose pliers, remove

~NOTE the oil seal.
Identify HLA(Hydrau/ic Lash Adjuster), valves, valve
springs as they are removed so that each item can be 6) Using a magnetic finger, remove the spring seat.
reinstalled in its original position.
1. Remove HLAs (A).
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ECKD217A
2. Remove valves.
1) Using SST(09222-28000, 09222-281 00), com-

press the valve spring and remove retainer lock.
EDKD116A
2) Remove the spring retainer.
3) Remove the valve spring.

INSPECTION EEDB2EDC 3. Inspect valve stems and valve guides.
1. Inspect for flatness. 1) Using a caliper gauge, measure the inside diam-
Using a precision straight edge and feeler gauge, eter or the valve guide.
measure the surface the contacting the cylinder block Valve guide inside.
and the manifolds for warpage.
Flatness of cylinder head gasket surface

Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.05 mm ( 0.002 in.)
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ECKD219A
2) Using a micrometer, measure the diameter of the

valve stem.
ECKD001H
2. Inspect for cracks.

Check the combustion chamber, intake ports, exhaust
ports and cylinder block surface for cracks. If cracked,
replace the cylinder head.
ECKD220A
3) Subtract the valve stem diameter measurement 5. Inspect valve seats

from the valve guide inside diameter measure- Check the valve seat for evidence of overheating and
ment. improper contact with the valve face.
Valve stem-to-guide clearance Replace the seat if necessary.
Before reconditioning the seat, check the valve guide
[Standard] for wear. If the valve guide is worn, replace it, then
Intake: 0.03- 0.06mm (0.0012- 0.0024in.) recondition the seat. Recondition the valve seat with
Exhaust : 0.05 - 0.08mm (0.002 - 0.0031 in.) a valve seat grinder or cutter. The valve seat contact
[Limit] width should be within specifications and centered on
Intake : 0.1 mm (0.0040in.) the valve face.
Exhaust : 0.15mm (0.0059in.)
6. Inspect valve springs.
If the clearance is greater than maximum, replace 1) Using a steel square, measure the out-of-square
the valve and valve guide. of the valve spring.
4. Inspect valves. 2) Using a vernier calipers, measure the free length
of the valve spring.
1) Check the valve is ground to the correct valve
face angle. Valve spring
[Standard)
2) Check that the surface of the valve for wear.
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Free height : 44mm (1.7323 in.)
If the valve face is worn, replace the valve.
Load : 21.6kg I 35 mm (47.6 lb I 1.378in.)
3) Check the valve head margin thickness. [Limit]
If the margin thickness is less than minimum, re- Free height: -1.0 mm( -0.0394 in.)
place the valve. Out-of-square : 3°
Margin
[Standard)
Intake : 1.1 mm(0.043 in.)
Exhaust : 1.3 mm(0.051 in.)
[Limit)
Intake: 0.8 mm(0.0315 in.)
Exhaust : 1.0mm(0.040 in.)
ECKD222A
If the free length is not as specified, replace the

valve spring.
ECKD221A
4) Check the surface of the valve stem tip for wear.

If the valve stem tip is worn, replace the valve.
7. Inspect cam lobes. 3) Lay a strip of plastigage across each of the

Using a micrometer, measure the cam lobe height. camshaft journal.
Cam height
[Standard value]
Intake: 43.4484 mm (1.7106 in.)
Exhaust : 43.8489 mm (1.7263 in.)
[Limit]
Intake : 42.9484 mm (1.6909 in.)
Exhaust : 43.3489 mm (1.7066 in.)
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ECKD224A
4) Install the bearing caps.(see page EMA-41)
ffi CAUTION
Do not turn the camshaft.
5) Remove the bearing caps.

ECKD223A
If the cam lobe height is less than minimum, replace

the camshaft.
8. Inspect camshaft journal clearance.
1) Clean the bearing caps and camshaft journals.
2) Place the camshafts on the cylinder head.

6) Measure the plastigage at its widest point. 9. Inspect camshaft end play.
Bearing oil clearance : 1) Install the camshafts.(see page EMA-41 ).

[Standard value] :
0.035 - 0.072mm(0.0014 - 0.0028in.) 2) Using a dial indicator, measure the end play while
[Limit] : 0.1 mm(0.0039in.) moving the camshaft back and forth.
Camshaft end play

[Standard value] : 0.1 - 0.2mm(0.004 - 0.008in.)
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ECKD225A
If the oil clearance is greater than maximum, re-

place the camshaft. If necessary, replace the EDKD117A
bearing caps and cylinder head as a set.

If the end play is greater than maximum, replace
7) Completely remove the plastigage. the camshaft. If necessary, replace the bearing
caps and cylinder head as a set.
8) Remove the camshafts.
3) Remove the camshafts.
REPLACEMENT EC85ACCB 3. Using the SST(service special tool: 09221-3F1 00

AlB), press-fit the valve guide. The valve guide must
VALVE GUIDE be press-fitted from the upper side of the cylinder
head. Keep in mind that the intake and exhaust valve
1. Using the SST(service special tool: 09221-3F1 00 A), guides are different in length.
withdraw the old valve guide toward the bottom of
cylinder head. Over size Size Oversize valve guide
mm(in.) mark hole size mm(in.)
EDKD900A 11 .05 - 11 .068
0.05 (0.002) 5
(0.4350 - 0.4357)
2. Recondition the valve guide hole so that it can match
the newly press-fitted oversize valve guide. 11 .25 - 11 .268
0.25 (0.01 0) 25
(0.4429 - 0.4436)
11.50-11.518
0.50 (0.020) 50
(0.4528 - 0.4535)
Valve guide length

Intake : 36.5mm (1.44in.)
Exhaust: 41mm (1.61in.)
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EDKD9006
4. After the valve guide is press-fitted, insert a new valve

and check for proper stem -to-guide clearance.
5. After the valve guide is replaced, check that the valve

is seated properly. Recondition the valve seats as
necessary.
REASSEMBLY EB6C7C59 4) Using the SST{09222-28000,09222-281 00),

compress the spring and install the retainer
[QJ) NOTE locks. After installing the valves, ensure that
the retainer locks are correctly in place before
Thoroughly clean all parts to be assembled. releasing the valve spring compressor.
Before installing the parts, apply fresh engine oil to all
sliding and rotating surfaces.
Replace oil seals with new ones.
1. Install valves.
1) Install the spring seats.
2) Using SST{09222-22001 ), push in a new oil seal.
~NOTE
Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leak-
age past the valve guides.
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EDKD116A
5) Lightly tap the end of each valve stem two or

three times with the wooden handle of a hammer
to ensure proper seating of the valve and retainer
lock.
EDKD120A
3) Install the valve, valve spring and spring retainer.
[QJ) NOTE
Place valve springs so that the side coated with
enamel faces toward the valve spring retainer and
then installs the retainer.
EDKD121A
2. Install HLA. INSTALLATION EDC50BC9
Check that the HLA rotates smoothly by hand.

(gJ) NOTE
• Thoroughly clean all parts to be assembled.
• Always use a new head and manifold gasket.
• The cylinder head gasket is a metal gasket. Take
care not to bend it.
• Rotate the crankshaft, set the No. 1 piston at
TDC(see page EMA-9).
1. Install the cylinder head gasket (A) on the cylinder

block.
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ECKD217A
ECKD231A
[QJ) NOTE
Be careful of the installation direction.
2. Place the cylinder head quietly in order not to damage

the gasket with the bottom part of the end.
3. Install cylinder head bolts.
1) Apply a light coat if engine oil on the threads and

under the heads of the cylinder head bolts.
2) Using 8mm hexagon wrench, install and tighten 2) Install the camshafts (A) and bearing caps (B).
the 10 cylinder head bolts and plate washers, in
several passes, in the sequence shown. Tightening torque
12- 14Nm (120- 140kgf.cm, g- 101bf.ft)
Tightening torque
30Nm (300kgf.cm, 221bf.ft) +goo~ Release all bolts
~ 30Nm (300kgf.cm, 221bf.ft) + goo
8 6 3 9
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10 4 2 5 7
EDKD124A
EDKD700A 5. Using the SST (Og221-21000), install the camshaft

bearing oil seal.
4. Install the camshafts.
1) Align the camshaft timing chain with the intake

timing chain sprocket and exhaust timing chain
sprocket as shown.
09221-21000
EDKD125A
6. Install the camshaft sprocket.(see page EMA-22).
EDKD123A 7. Install the timing belt(see page EMA-22).

8. Install the cylinder head cover. 2) Apply liquid gasket to the head cover gasket at
the corners of the recess.
1) Install the cylinder head cover gasket (A) in the
groove of the cylinder head cover (B).
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EDKD127A
EDKD126A [gJ) NOTE

• Use liquid gasket, loctite No. 5999.
(Q] NOTE • Check that the mating surfaces are clean and dry
• Before installing the head cover gasket, thor- before applying liquid gasket
oughly clean the head cover gasket and the • After assembly, wait at least 30 minutes before
groove. filling the engine with oil.
• When installing, make sure the head cover gas-
ket is seated securely in the corners of the re-
cesses with no gap.
3) Install the cylinder head cover (A) with the 1Obolts 16. Install the PCSV hose (A).
(B). Uniformly tighten the bolts in several passes.
Tightening torque
8 - 1ONm (80 - 1OOkgf.cm, 6 - 7.4 lbf.ft)
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EDKD113C
17. Install the fuel inlet hose (A).
EDKD104A
9. Install the intake manifold.(see page EMA-96).
10. Install the exhaust manifold(see page EMA-97).
11. Install the PCV.
12. Install the spark plug cable.
13. Install the power steering pump. (see ST group -

power steering pump)
14. Install the accelerator cable.
15. Install the bake booster hose.

EDKD113A
18. Install the engine wire harness connectors and wire 5) CMP connector.
harness clamps to the cylinder head and the intake
manifold. 6) ISA connector.
1) PCSV connector. 7) TPS connector (A).
2) Front heated oxygen sensor connector (A).
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EDKD112A
ECKD206A 8) Ignition coil connector (A).
3) Knock sensor connector (B). 9) ECT sensor connector.
4) Four fuel injector connectors (A).
EDKD112C
EDKD701A
19. Install the heater hoses (A).
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KCPC003F
20. Install the upper radiator hose (A) and lower radiator
hose (B).
EDK0112B
21. Install the intake air hose and air cleaner assembly.
22. Install the engine cover.
23. Connect the negative terminal to the battery.
24. Filii with engine coolant.
25. Start the engine and check for leaks.
26. Recheck engine coolant level and oil level.

ENGINE AND TRANSAXLE 4. Remove the intake air hose and air cleaner assembly.
ASSEMBLY 1) Remove the heat shield.
REMOVAL E12FDDBB
& CAUTION
• Use fender covers to avoid damaging painted
surfaces.
• To avoid damage, unplug the wiring connec-
tors carefully while holding the connector
portion.
[QJ) NOTE
• Mark all wiring and hoses to avoid misconnec-
tion.
• Inspection the timing belt before removing the
cylinder head. A
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• Turn the crankshaft pulley so that the No. 1 piston
is at top dead center. (See page EMA-9)
1. Disconnect the neagative terminal from the battery. ECKD600A
2) Disconnect the breather hose from air cleaner

hose.
3) Remove the intake air hose and air cleaner.
5. Remove the upper radiator hose (A) and lower radia-

tor hose (B).
ECKD201B
3. Drain the engine coolant (see page EMA-79)

Remove the radiator cap to speed draining. EDKD112B
ENGINE AND TRANSAXLE ASSEMBLY EMA -47
6. Remove the heater hoses. 3) TPS {Throttle Position Sensor) connector {A).
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KCPC003F
EDKD112A
7. Remove the engine wire harness connectors and wire

4) ISA {Idle Speed Actuator) connector.
harness clamps from the cylinder head and the intake
manifold.
5) CMP {Camshaft Position Sensor) connector.
1) ECT {Engine Coolant Temperature) sensor con-
nector. 6) Four fuel injector connectors {A).
2) Ignition coil connector {A). 7) Knock sensor connector {B).
EDKD112C EDKD701A
8) Front heated oxygen sensor (A) connector. 9. Remove the PCSV hose (A).
I A
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ECKD206A EDKD113C
9) PCSV (Purge Control Solenoid Valve) (A) con- 10. Remove the brake booster vacuum hose(A).
nector.
8. Remove the fuel inlet from delivery pipe (A).

A
KCPC003B
11. Remove the accelerator cable by loosening the lock-

EDKD113A nut, then slip the cable end out of the throttle linkage.
12. Remove the power steering pump. (see ST group -

power steering pump)
21. Remove the start motor cable mounting bolts (A). 25. Remove the engine mounting bracket (A).
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ECKD609A EDKD101A
22. Remove the starting motor connector. 26. Remove the transaxle mounting bracket (A).
23. Remove the alternator connector.
24. Install the special tool (09200-38001, 09200-1 COOO),

the engine support fixture and the adapter, on the
engine and transaxle assembly.
ECKD611A
27. Remove the front tires.
ECKD610A
17. Remove the clip (A) of the control cable. 19. Remove the output shaft speed sensor connector (A).
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ECKD605A ECKD607A
18. Remove the input shaft speed sensor connector (A). 20. Remove the transaxle earth cable (A).
A
17=,}1
iL_J
ECKD606A ECKD608A
13. Disconnect the inhibitor switch and solenoid valve 15. Remove the vehicle speed sensor connector {A).
connector (A).
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ECKD603A
ECKD601A
16. Remove the control cable transaxle range switch nut
14. Remove the transaxle range switch connector (A). {A).
ECKD602A ECKD604A
30. Remove the knuckle mounting bolts (A). 32. Disconnect the rear oxygen sensor connector (A).
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KXDSE34A
ECKD614A
31. Remove the power steering return hose (A) and drain
the power steering oil. 33. Remove the front muffler (A).
~{~~~1~~ ~,)))
- P~~c-~-- -- A
ECKD613A ECKD615A
28. Remove the ABS wheel speed sensor (A). 29. Remove the caliper and hang the caliper assembly
(A).
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KXDSE03A
KMOB024A
ECKD612A
EMA -54 ENGINE MECHANICAL SYSTEM [1.6 DOHC)
34. Remove the steering u-joint mounting bolt (A). 35. Remove the sub frame bolts (A).
\
Sf:
~=-~-=---= ~~ ~
~~~~~/;
A
A
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ECKD616A ECKD617A
ECKD618A
36. Remove the engine support fixture and the adapter.
37. Jack up the vehicle.

INSTALLATION EE2DB283
Installation is in the reverse order of removal.
Perform the following :

• Adjust the shift cable.
• Adjust the throttle cable.
• Refill the engine with engine oil.
• Refill the transaxle with fluid.
• Refill the radiator with engine coolant.
• Bleed air from the cooling system with the heater
valve open.
• Clean the battery posts and cable terminals with
sandpaper assemble them, then apply grease to
prevent corrosion.
• Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition
switch (do not operate the starter) so that the fuel
pump runs for approximately two seconds and fuel
line pressureizes.
Repeat this operation two or three times, then check
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for fuel leakage at any point in the fuel line.
ENGINE BLOCK
COMPONENT EOC14DEE
(ATA)
Drive plate
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Rear oil seal case
Gasket
Cylinder block
Front case
10-12 (100- 120,7.3- 8.8)

Gasket
Oil pan

EDKD140A
ENGINE BLOCK EMA -57
~ p;,tonring
P;stonp;n~
Connecting rod
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~ 32- 35 (320- 350, 24- 26)
EDKD141A
DISASSEMBLY E6CF12FE 8. Remove oil pressure sensor (A).
1· M!T : remove flywheel.
2· AfT : remove drive plate.
3. Install engine to engine stand for disassembly.
4. Remove timing belt(see page EMA-17).
5. Remove cylinder head(see page EMA-29)
6. Remove oil level gauge assembly (A).
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ECKD303A
9. Remove water pump.(see page EMA-81)
10. Remove oil pan (A).
ECKD301A
7. Remove knock sensor (A).
EDKD142A
ECKD302A
11. Remove oil screen. 16. Remove rear oil seal case.
Remove the 2bolts (C), oil screen (A) and gasket (B). Remove the 5 bolts (B) and rear oil seal case (A).
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EDKD143A EDKD144A
12. Check the connecting rod end play. 17. Remove crankshaft bearing cap and check oil clear-
(see page EMA-60) ance.(see page EMA-63)
13. Remove the connecting rod caps and check oil clear- 18. Check the crankshaft end play.(see page EMA-65)
ance.(see page EMA-61)
19. Lift the crankshaft (A) out of the engine, being careful
14. Remove piston and connecting rod assemblies. not to damage journals.
1) Using a ridge reamer, remove all the carbon from

~NOTE
the top of the cylinder.
Arrange the main bearings and trust washers in the
2) Push the piston, connecting rod assembly and correct order.
upper bearing through the top of the cylinder
block.
[gJ) NOTE
• Keep the bearings, connecting rod and cap to-
gether.
• Arrange the piston and connecting rod assem-
blies in the correct order.
15. Remove front case. (see page EMA-94)
ECKD307A
20. Check fit between piston and piston pin. INSPECTION E313099C
Try to move the piston back and forth on the piston

pin. If any movement is felt, replace the piston and CONNECTING ROD AND CRANKSHAFT
pin as a set.
1. Check the connecting rod end play.
21. Remove piston rings. Using a feeler gauge, measure the end play while
moving the connecting rod back and forth.
1) Using a piston ring expender, remove the 2 com-
pression rings. Standard end play : 0.1- 0.25mm(0.004 - 0.01 Oin.)
Maximum end play : 0.4mm(0.016in.)
2) Remove the 2side rails and oil ring by hand.
[Q) NOTE
Arrange the piston rings in the correct order only.
22. Disconnect connecting rod from piston.
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EDKD145A
• If out-of-tolerance, install a new connecting rod.

• If still out-of-tolerance, replace the crankshaft.
2. Check the connecting road bearing oil clearance.
1) Check the match marks on the connecting rod

and cap are aligned to ensure correct reassem-
bly.
2) Remove the 2 connecting rod cap nuts.
3) Remove the connecting rod cap and bearing half.
4) Clean the crank pin and bearing.
5) Place plastigage across the crank pin.
6) Reinstall the bearing half and cap, and torque the

nuts.
Tightening torque :
32 - 35 Nm (320 - 350kgf.cm, 24 - 261bf.ft)
[Q) NOTE
Do not turn the crankshaft.
7) Remove the 2 nuts, connecting rod cap and bear- 10) If the plastigage shows the clearance is still in-
ing half. correct, try the next larger or smaller bearing (the
color listed above or below that one), and check
8) Measure the plastigage at its widest point. clearance again.
Standard oil clearance :

~NOTE
0.018 - 0.036mm(0.0007 - 0.0014in.)
If the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace the
crankshaft and start over.
ffi CAUTION
If the marks are indecipherable because of an ac-
cumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with
solvent or detergent.
Connecting rod mark location
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ECKD309A
9) If the plastigage measures too wide or too nar- Mark

row, remove the upper half of the bearing, in-
stall a new, complete bearing with the same color
mark (select the color as shown in the next col-
umn), and recheck the clearance.
& CAUTION
Do not file, shim, or scrape the bearings or the
caps to adjust clearance. EDKD146A
Discrimination of connecting rod
CLASS MARK INSIDE DIAMETER

48.00 - 48.006mm
a 1\
(1.8896 - 1.8899in.)
48.006 - 48.012mm
b b
(1.8899 - 1.8902in.)
48.012 - 48.018mm
c c
(1.8902 - 1.8904in.)
Crankshaft pin mark location Place of identification mark (Connecting rod

bearing)
EDKD145B
Discrimination of crankshaft
OUTSIDE
CLSASS MARK
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DIAMETER OF PAN
ECKD313A
44.966 - 44.972mm
I (\
(1.7703- 1.7706in.) Discrimination of connecting rod bearing
44.960 - 44.966mm
II b
(1.7700- 1.7703in.) THICKNESS OF
CLASS MARK
BEARING
44.954- 44.960mm
Ill c 1.514 - 1.517mm
(1.7697- 1.7700in.)
AA BLUE
(0.0596 - 0.0597in.)
1.511 - 1.514mm
A BLACK
(0.0595 - 0.0596in.)
1.508- 1.511mm
B NONE
(0.0594- 0.0595in.)
1.505 - 1.508mm
c GREEN
(0.0593 - 0.0594in.)
1.502 - 1.505mm
D YELLOW
(0.0591 - 0.0593in)
11) Selection 5) Remove the cap and bearing again, and measure
the widest part of the plastigage.
CONNECT- ASSEMBING
CRANKSHAFT
lNG ROD CLASSIFI- Bearing oil clearance
INDENTIFICATION
IDENTIFICA- CATION OF No. 1, 2, 4, 5 : 0.022 - 0.040mm (0.0009 - 0.0016in.)
MARK
TION MARK BEARING No. 3: 0.028- 0.046mm (0.0011 - 0.0018in.)
a (A) D (YELLOW)
I (A) b (b) C (GREEN)
c (c) B (NONE)
a (A) C (GREEN)
II (b) b (b) B (NONE)
c (c) A (BLACK)
a (A) B (NONE)
Ill (c) b (b) A (BLACK)
c (c) AA (BLUE)
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3. Check the crankshaft bearing oil clearance.
1) To check main bearing-to-journal oil clearance,

remove the main caps and bearing halves.
2) Clean each main journal and bearing half with a ECKD0011

clean shop tower.
6) If the plastigage measures too wide or too nar-
3) Place one strip of plastigage across each main row, remove the upper half of the bearing, in-
journal. stall a new, complete bearing with the same color
mark (select the color as shown in the next col-
4) Reinstall the bearings and caps, then torque the
umn), and recheck the clearance.
bolts.
Tightening torque: & CAUTION

55- 60Nm (550- 600kgf.cm, 41 - 441bf.ft) Do not file, shim, or scrape the bearings or the
caps to adjust clearance.
[QJ) NOTE 7) If the plastigage shows the clearance is still in-
Do not turn the crankshaft. correct, try the next larger or smaller bearing (the
color listed above or below that one), and check
clearance again.
[QJj NOTE
If the proper clearance cannot be obtained by using
the appropriate larger or smaller bearings, replace the
crankshaft and start over.
& CAUTION
If the marks are indecipherable because of an ac-
cumulation of dirt and dust, do not scrub them
with a wire brush or scraper. Clean them only with
solvent or detergent.
Connecting rods Discrimination of cylinder block
1. When reinstalling, make sure that cylinder numbers CALSS MARK INSIDE DIAMETER
put on the connecting rod and cap at disassembly
match. When a new connecting rod is installed, make 54.000 - 54.006mm
a (\
sure that the notches for holding the bearing in place (2.1260 - 2.1262in.)
are on the same side. 59.006 - 59.012mm
b b
2. Replace the connecting rod if it is damaged on the (2.1262 - 2.1264in.)
thrust faces at either end. Also if step wear or a
59.012 - 59.018mm
severely rough surface of the inside diameter of the c c
(2.1264 - 2.1267in.)
small end is apparent, the rod must be replaced as
well.
3. Using a connecting rod aligning tool, check the rod for Crankshaft journal mark location
bend and twist. If the measured value is close to the
repair limit, correct the rod by a press. Any connecting
rod that has been severely bent or distorted should be
replaced.
Allowable bend of connecting rod :

0.05mm I 1OOmm (0.0020 in./3.94 in.) or less
Allowable twist of connecting rod :
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0.1 mm I 1OOmm (0.0039 in./3.94 in.) or less
Crankshaft bore mark location
Letters have been stamped on the end of the block as

a mark for the size of each of the 5 main journal bores.
Use them, and the numbers or bar stamped on the

crank (marks for main journal size), to choose the cor-
rect bearings.
EDKD148A
Discrimination crankshaft
OUTSIDE
CLASS MARK DIAMETER OF
JOURNAL
49.962 - 49.968mm
I (\
(1.9670 - 1.9672in.)
49.956 - 49.962mm
II b
(1.9667 - 1.9670in.)
49.950 - 49.956mm
Ill c (1.9665 - 1.9667in.)
EDKD147A
Place of identification mark (Crankshaft bearing) Selection
CRANK- ASSEM-
CRANKSHAFT
SHAFT BORE BLING CLAS-
IDENTIFICATION
IDENTIFICA- SIFICATION
MARK
TION MARK OF BEARING
a (A) D (YELLOW)
I (A) b (b) C (GREEN)
c (c) B (NONE)
a (A) C (GREEN)
II (b) b (b) B (NONE)
c (c) A (BLACK)
a (A) B (NONE)
Ill (c) b (b) A (BLACK)
c (c) AA (BLUE)
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ECKD316A
4. Check crankshaft end play.
Discrimination of crankshaft bearing Using a dial indicator, measure the thrust clearance
while prying the crankshaft back and forth with a
THICKNESS OF BEARING screwdriver.
CLASS MARK mm(in.)
Standard end play : 0.06 - 0.26mm (0.0023 - 0.01 Oin.)
No. 1, 2, 4, 5 No. 3 Limit : 0.30mm (0.0118in.)
2.014-2.017 2.011-0.014
AA BLUE
(0.0793-0.0794) (0.0791-0.0793)
2.011 -2.014 2.008-2.011
A BLACK
(0.0791-0.0793) (0.0790-0.0791)
2.008-2.011 2.005-2.008
B NONE
(0.0790-0.0791) (0.0789-0.0790)
2.005-2.008 2.002-2.005
c GREEN
(0.0789-0.0790) (0.0788-0.0789)
YEL- 2.002-2.005 1.999-2.002
D
LOW (0.0788-0.0789) (0.0787 -0.0788)
ECKD0016
If the end play is greater than maximum, replace the

center bearing as a set.
5. Inspect main journals and crank pins CYLINDER BLOCK

Using a micrometer, measure the diameter of each
main journal and crank pin. 1. Remove gasket material.
Using a gasket scraper, remove all the gasket material
Main journal diameter : 50mm (1.969in.) from the top surface of the cylinder block.
Crank pin diameter: 45mm (1.77in.)
2. Clean cylinder block
Using a soft brush and solvent, thoroughly clean the
cylinder block.
3. Inspect top surface of cylinder block for flatness.

Using a precision straight edge and feeler gauge,
measure the surface contacting the cylinder head
gasket for warpage.
Flatness of cylinder block gasket surface

Standard : Less than 0.03mm(0.0012 in.)
Limit : 0.06 mm ( 0.0024 in.)
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ECKD001E
ECKD001L
4. Inspect cylinder bore diameter

Visually check the cylinder for vertical scratchs.
If deep scratches are present, replace the cylinder
block.
5. Inspect cylinder bore diameter Size

Using a cylinder bore gauge, measure the cylinder Class Cylinder bore inner diameter
code
bore diameter at position in the thrust and axial di-
rections. A 76.50 - 76.51 mm (3.0118- 3.0122in.) A
B 76.51 - 76.52mm (3.0122- 3.0126in.) B
Standard diameter :
76.50 - 76.53mm (3.0118 - 3.0130in.)
c 76.52 - 76.53mm (3.0126- 3.0130in.) c
7. Check the piston size code (A) on the piston top face.
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ECKD318A
ECKD320B
6. Check the cylinder bore size code on the cylinder
block bottom face.
@)NOTE
Stamp the grade mark of basic diameter with rubber
stamp.
Size
Class Piston outer diameter
code
A 76.47- 76.48mm (3.01 06- 3.011 Oin.) A
B 76.48- 76.49mm (3.011 0- 3.0114in.) B
c 76.49- 76.50mm (3.0114- 3.0118in.) c
8. Select the piston related to cylinder borre class.
Clearance :
0.02 - 0.04mm (0.00078 - 0.00157in.)
EDKD147A
BORING CYLINDER PISTON AND RINGS
1. Oversize piston should be selected according to the 1. Clean piston

largest bore cylinder.
1) Using a gasket scraper, remove the carbon from
Identification Mark Size the piston top.
0.25 0.25mm (0.01 Oin.) 2) Using a groove cleaning tool or broken ring, clean
the piston ring grooves.
@)NOTE 3) Using solvent and a brush, thoroughly clean the
The size of piston is stamped on top of the piston. piston.
2. Measure the outside diameter of the piston to be ~NOTE

used.
Do not use a wire brush.
3. According to the measured O.D., calculate the new
bore size. 2. The standard measurement of the piston outside di-
ameter is taken 39.35mm (1.55in.) from the top land
New bore size = Piston O.D + 0.02 to 0.04 mm of the piston.
(0.0008 to 0.0016 in.) (clearance between piston and
cylinder) - 0.01 mm (0.0004 in.) (honing margin.) Standard diameter :
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76.47 - 76.50mm (3.01 0 - 3.012in.)
4. Bore each of the cylinders to the calculated size.
& CAUTION
To prevent distortion that may result from temper-
ature rise during honing, bore the cylinder holes
in the firing order.
5. Hone the cylinders, finishing them to the proper di-

mension (piston outside diameter+ gap with cylinder).
6. Check the clearance between the piston and cylinder.
Standard : 0.02-0.04 mm (0.0008-0.0016 in.)
@)NOTE
When boring the cylinders, finish all of the cylinders
to the same oversize. Do not bore only one cylinder
to the oversize.
ECKD001D
3. Calculate the difference between the cylinder bore di-

ameter and the piston diameter.
Piston-to-cylinder clearance :
0.02 - 0.04mm(0.0008 - 0.0016in.)
4. Inspect the piston ring side clearance. 5. Inspect piston ring end gap.
Using a feeler gauge, measure the clearance between To measure the piston ring end gap, insert a piston
new piston ring and the wall of the ring groove. ring into the cylinder bore. Position the ring at right
angles to the cylinder wall by gently pressing it down
Piston ring side clearance with a piston. Measure the gap with a feeler gauge. If
No. 1 : 0.04 - 0.085 mm (0.0016 - 0.0033 in.) the gap exceeds the service limit, replace the piston
No. 2 : 0.04 - 0.085 mm (0.0016 - 0.0033 in.) ring. If the gap is too large, recheck the cylinder bore
Limit diameter against the wear limits on page EMA-68 , If
No. 1 : 0.1 mm (0.004in.) the bore is over the service limit, the cylinder block
No. 2 : 0.1 mm (0.004in.) must be rebored.(see page EMA-68).
Piston ring end gap

Standard
No. 1 : 0.15 - 0.30mm (0.0059 - 0.0118in.)
No. 2 : 0.30 - 0.45mm (0.0118 - 0.0177in.)
Limit
No. 1, 2, oil ring : 1.0mm (0.039in.)
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ECKD001G
If the clearance is greater than maximum, replace the

piston. .. ··~~
ECKD001K
PISTON PINS OIP PRESSURE SWITCH
1. Measure the diameter of the piston pin. 1. Check the continuity between the terminal and the
body with an ohmmeter.
Piston pin diameter : If there is no continuity, replace the oil pressure
18.001 - 18.007mm (0.7087- 0.7089in.) switch.
0
l
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ECKD001W
ECKD001Z
2. Check the continuity between the terminal and the

2. Measure the piston pin-to-piston clearance. body when the fine wire is pushed. If there is con-
tinuity even when the fine wire is pushed, replace the
Piston pin-to-piston clearance : switch.
0.007 - 0.022mm (0.00028 - 0.00087in.)
3. Check the difference between the piston pin diameter

and the connecting rod small end diameter.
Piston pin-to-connecting rod interference :

0.016 - 0.032mm (0.00063 - 0.00126in.)
3. If there is no continuity when a 50kpa (?psi) vacuum REASSEMBLY EE463EOB
is applied throgh the oil hole, the switch is operaing

properly. ~NOTE
Check for air leakage. If air leaks, the diahragm is
broken. Replace it. • Thoroughly clean all parts to assembled.
• Before installing the parts, apply fresh engine oil
Operation Pressure to all sliding and rotating surfaces.
Oil pressure switch : • Replace all gaskets, 0-rings and oil seals with
80kpa (0.8kg/cm 2 , 11.4psi) or more @700rpm new parts.
1. Assemble piston and connecting rod.
1) Use a hydraulic press for installation.
2) The piston front mark and the connecting rod

front mark must face the timing belt side of the
engine.
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ECKD001Y
ECKD320A
2. Install piston rings. 4. Install main bearings.
1) Install the oil ring expander and 2 side rails by

~NOTE
hand.
Upper 1, 2, 3, 4, 5 bearings have an oil groove of oil
2) Using a piston ring expander, install the 2 com- holes; Lower bearings do not.
pression rings with the code mark facing upward.
1) Align the bearing claw with the claw groove of the
3) Position the piston rings so that the ring ends are cylinder block, push in the 4 upper bearings (A).
as shown.
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EDKD149A
ECKD321A
2) Align the bearing claw with the claw groove of
3. Install connecting rod bearings. the main bearing cap, and push in the 5 lower
bearings.
1) Align the bearing claw with the groove of the con-
necting rod or connecting rod cap. 5. Install center bearing (A).
Install the center bearing under the No.3 journal po-
2) Install the bearings (A) in the connecting rod and sition of the cylinder block with the oil groove facing
connecting rod cap (B). upward.
ECKD322A EDKD150A
6. Place crankshaft on the cylinder block. 10. Install piston and connecting rod assemblies.
7. Place main bearing caps on cylinder block. [g NOTE

8. Install main bearing cap bolts. Before installing the pistons, apply a coat of engine oil
to the ring grooves and cylinder bores.
@)NOTE
1) Remove the connecting rod caps, and slip short
• The main bearing cap bolts are tightened in 2 sections of rubber hose over the threaded ends
progressive steps. of the connecting rod bolts.
• If any of the bearing cap bolts in broken or de-
formed, replace it. 2) Install the ring compressor, check that the bear-
ing is securely in place, then position the piston in
1) Apply a light coat of engine oil on the threads and the cylinder, and tap it in using the wooden han-
under the bearing cap bolts. dle of a hammer.
2) Install and uniformly tighten the 10 bearing cap 3) Stop after the ring compressor pops free, and
bolts, in several passes, in the sequence shown. check the connecting rod-to-check journal align-
ment before pushing the piston into place.
Tightening torque
55- 60Nm (550- 600kgf.cm, 41 - 441bf.ft) 4) Apply engine oil to the bolt threads. Install the
rod caps with bearings, and torque the nuts : 32
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- 35Nm (320- 350kgf.cm, 24- 261bf.ft)
(QJ1 NOTE
Maintain downward force on the ring compressor to
prevent the rings from expanding before entering the
cylinder bore.
EDKD151A
3) Check that the crankshaft turns smoothly.
9. Check crankshaft end play.(see page EMA-65)
ECKD001F
11. Install a new gasket and rear oil seal case (A) with 5 13. Install front case.(see page EMA-94)
bolts (B).
14. Install oil screen.
Tightening torque Install a new gasket (B) and oil screen (A) with 2 bolts
10 - 12Nm (1 00 - 120kgf.cm, 7.3 - 8.81bf.ft) (C).
Tightening torque
15 - 22Nm (150 - 220kgf.cm, 11 - 161bf.ft)
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EDKD144A
[Q"JJ NOTE
EDKD143A
Check that the mating surfaces are clean and dry.
15. Install oil pan.
12. Install rear oil seal.
1) Using a razor blade and gasket scraper, remove
1) Apply engine oil to a new oil seal lip. all the old packing material from the gasket sur-
faces.
2) Using SST(09231-21000) and a hammer, tap in
the oil seal until its surface is flush with the rear
oil seal retainer edge. @)NOTE
Check that the mating surfaces are clean and dry be-
fore applying liqued gasket.
2) Apply liquid gasket as an even bead, centered

between the edges of the mating surface.
Use liquid gasket MS 721-40A or equivalent.
@)NOTE
• To prevent leakage of oil, apply liquid gasket to
the inner threads of the bolt holes.
• Do not install the parts if five minutes or more
have elapsed since applying the liquid gasket.
Instead, reapply liquid gasket after removing the
residue.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
ECKD326A
3) Install the oil pan (A) with the 19 bolts. 18. Install knock sensor (A).
Uniformly tighten the bolts in several passes.
Tightening torque
Tightening torque 17- 27Nm (170- 270kgf.cm, 12.5- 201bf.ft)
10- 12Nm (100- 120kgf.cm, 7.3- 8.81bf.ft)
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ECKD302A
EDKD142A
19. Install oil level gauge assembly.

16. Install water pump. (see page EMA-86)
1) Install a new 0-ring on the oil level gauge.
17. Install oil pressure sensor.
2) Apply engine oil on the 0-ring.
1) Apply adhesive to 2 or 3 threads.
Adhesive : MS 721-39(8) or equivalent.
3) Install the oil level gauge assembly (A) with the
2) Install the oil pressure sensor (A). bolt.
Tightening torque Tightening torque

15 - 22Nm (150 - 220kgf.cm, 11 - 161bf.ft) 12- 15Nm (120- 150kgf.cm, 9- 111bf.ft
ECKD303A ECKD301A
20. Install cylinder head. (see page EMA-40)
21. Install timing belt. (see page EMA-22)
22. Remove engine stand.
23. AfT : Install drive plate.
Tightening torque
120 - 130Nm (1200 - 1300kgf.cm, 89 - 961bf.ft)
24. MfT : Install flywheel.
Tightening torque
120 - 130Nm(1200 - 1300kgf.cm, 89 - 961bf.ft)
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COOLING SYSTEM EMA -77
COOLING SYSTEM
COMPONENT E83ACE50
Upper bracket
dl
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Radiator lower
Reservior
tank
' Lower insulator
Fan motor
ECKD011A
15- 20 (150- 200,

9-14) \
Thermostat housing
Thermostat
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10- 15 (100- 150, 7- 9)
12- 15
(120- 150,8.8- 11)
EDKD180A
ENGINE COOLANT REFILLING AND 4. Tighten the radiator drain plug (A) securely.
BLEEDING E6489BEE 5. Remove, drain and reinstall the reservoir. Fill the tank
halfway to the MAX mark with water, then up to the
ffi CAUTION MAX mark with antifreeze.
When pouring engine coolant, be sure to shut the
6. Mix the recommended antifreeze with an equal
relay box lid and not to let coolant spill on the
amount of water in a clean container.
electrical parts or the paint. If any coolant spills,
rinse it off immediately.
~NOTE
1. Slide the heater temperature control lever to maxi- • Use only genuine antifreeze/coolant.
mum heat. Make sure the engine and radiator are • For best corrosion protection, the coolant con-
cool to the touch. centration must be maintained year-round at 50%
minimum. Coolant concentrations less than 50%
2. Remove radiator cap (A). may not provide sufficient protection against cor-
rosion or freezing.
• Coolant concentrations greater then 60% will im-
pair cooling efficiency and are not recommended.
ffi CAUTION
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• Do not mix different brands of an-
tifreeze/coolants.
• Do not use additional rust inhibitors or anti-
rust products; they may not be compatible
with the coolant.
7. Pour coolant into the radiator up to base of the filler

neck, and install the radiator cap loosely.
8. Start the engine and let it run until it warms up (the

radiator fan comes on at least twice).
9. Turn off the engine. Check the level in the radiator,

add coolant if needed.
ECKD501Z
10. Put the radiatir cap on tightly, then run the engine
3. Loosen the drain plug, and drain the coolant. again and check for leaks.
KCPC001G
CAP TESTING TESTING
1. Remove the radiator cap, wet its seal with engine 1. Wait until engine is cool, then carefully remove the
coolant, then install it no pressure tester. radiator cap and fill the radiator with engine coolant,
then install it on the pressure tester.
2. Apply a pressure tester to the radiator and apply a

pressure of 93 - 123kPa (0.95 - 1.25kgf/cm2 14 -
18psi}.
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ECKD501X
2. Apply a pressure of 93- 123kPa (0.95- 1.25kgf/cm2 ,

14- 19psi)
3. Check for a drop in pressure. ECKD501Y
4. If the pressure drops, replace the cap. 3. Inspect for engine coolant leaks and a drop in pres-
sure.
4. Remove the tester and reinstall the radiator cap.
~NOTE
Check for engine oil in the coolant and/or coolant in
the engine oil.
REMOVAL ESAA92DB THERMOSTAT
WATER PUMP ~NOTE

1. Drain the engine coolant. Removal of the thermostat would have an adverse
effect, causing a lowering of cooling efficiency. Do
f) WARNING
not remove the thermostat, even if the engine tends
to overheat.
System is under high pressure when the engine is
hot. To avoid danger of releasing scalding engine 1. Drain engine coolant so its level is below thermostat.
coolant, remove the cap only when the engine is
cool. 2. Remove water inlet (A), gasket (B) and thermostat
(C).
2. Remove drive belts.
3. Remove the timing belt. (see page EMA-17)
4. Remove the water pump.
1) Remove the 4 bolts and pump pulley.
2) Remove the 1 bolt, then remove the alternator

brace (A).
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3) Remove the water pump (B) and gasket.
EDK0182A
EDKD181A
RADIATOR 3. Disconnect the fan motor connector.
1. Drain the engine coolant.
2. Remove the upper and lower radiator hoses (A), and

ATF cooler hoses.
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ECKD502A
ECKD501C
ECKD502B
4. Separate the air conditioner condenser with radiator.
1) Remove the heat shield.
2) Remove the battery and battery tray.

3) Remove the air duct (A) and make the task space. 5) Remove the 1Omm bolt.
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ECKD502C ECKD502E
4) Remove the reservoir tank (A) and make the task

space.
ECKD502F
ECKD502D
5. Remove the radiator upper bracket (A), then pull up

the radiator.
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ECKD502G
6. Remove the cooling fan from the radiator.

INSPECTION EBB4E96F THERMOSTAT
WATER PUMP 1. Immerse the thermostat in water and gradually heat

the water.
1. Check each part for cracks, damage or wear, and re-
place the coolant pump assembly if necessary.
2. Check the bearing for damage, abnormal noise and

sluggish rotation, and replace the coolant pump as-
sembly if necessary.
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ECKD503B
2. Check the valve opening temperature.
Valve opening temperature : 82 °C(177 °F)

Full opening temperature : 95 °C(205 °F)
EDKD183A
3. Check for coolant leakage. If coolant leaks form hole, If the valve opening temperature is not as specified,
the seal is defective. Replace the coolant pump as- replace the thermostat.
sembly
3. Check the valve lift.
~NOTE Valve lift: 8mm(0.3in.) or more at 95 °C{205 °F)

A small amount of "weeping" from the bleed hole is
normal. If the valve lift is not as specified, replace the thermo-
stat.
INSTALLATION EFEDBF7C THERMOSTAT
WATER PUMP 1. Place thermostat in thermostat housing.
1. Install the water pump. 1) Install the thermostat (C) with the jiggle valve up-
ward.
1) Install the water pump (C) and a new gasket with
the 4 bolts. 2) Install a new gasket (B) to the thermostat.
Tightening torque 2. Install water inlet (A).

A : 20 - 27Nm (200 - 270kgf.cm, 15 - 201bf.ft)
B : 12 - 15Nm (120 - 150kgf.cm, 8.8 - 111bf.ft) Tightening torque
15- 20Nm (150- 200kf.cm, 9- 141b.ft)
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A
EDKD181B
EDKD182A
2) Install the alternator brace (D) with the 1 bolt.

3. Fill with engine coolant.
3) Install the 4 bolts and pump pulley.
4. Start engine and check for leaks.
2. Install the timing belt.(see page EMA-22)
RADIATOR
3. Install drive belts.
1. Install the cooling fan to the radiator.
2. Install the radiator at the air conditioner condenser.
5. Start engine and check for leaks. Installation is in the reverse order of removal.
6. Recheck engine coolant level. 3. Connect the fan motor connector.
4. Install the upper and lower radiator hoses, and ATF

cooler hoses.
6. Start engine and check for leaks.

LUBRICATION SYSTEM EMA -87
LUBRICATION SYSTEM
COMPONENT mcs2As
20- 27 (200- 270, 15- 20)
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_/'I
_/
1
Gasket
/ ~ Oil screen
Front case
i /
'
L----
/
Drain plug~
40- 45 (400 -450,
30-33)
10- 12 (100- 120, 7.3- 8.8)
EDKD200A
Front case
Inner rotor
Gasket
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Pump cover
Outer rotor
' ' "'-, j:Y-

Oil filter
~ ~ {{;?,~
Relief pluoge• ' R e l i e f •pdog {jf}
Plug
40- 50 (400- 500,30- 37)

EDKD201A
OIL AND FILTER E6BEA1F6 INSPECTION
ffi CAUTION 1. Check engine oil quality

Check the oil for deterioration, entry of water, discol-
• Prolonged and repeated contact with mineral oring or thinning.
oil will result in the removal of natural fats If the quality is visibly poor, replace the oil.
from the skin, leading to dryness, irritation
and dermatitis. In addition, used engine oil 2. Check engine oil level.
contains potentially harmful contaminants After warming up the engine and then 5 minutes after
which may cause skin cancer. the engine stop, oil level should be between the "L"
• Exercise caution in order to minimize the and "F" marks on the dipstick.
length and frequency of contact of your skin If low, check for leakage and add oil up to the "F" mark.
to used oil. Wear protective clothing and
gloves. Wash your skin thoroughly with soap @)NOTE
and water, or use water-less hand cleaner,
Do not fill with engine oil above the "P' mark.
to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
• In order to preserve the environment, used oil
and used oil filter must be disposed of only at
designated disposal sites.
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1. Drain engine oil.
a. Remove the oil filter cap.
b. Remove the oil drain plug, and drain the oil into
a container.
2. Replace oil filter.

a. Remove the oil filter.
b. Check and clean the oil filter installation surface.
c. Check the part number of the new oil filter is as
same as old one.
d. Apply clean engine oil to the gasket of a new oil
filter.
e. Lightly screw the oil filter into place, and tighten
it until the gasket contacts the seat.
f. Tighten it an additional 3/4 turn.
3. Refill with engine oil filter.

a. Clean and install the oil drain plug with a new
gasket.
Tightening torque
40 - 45Nm (400 - 450kgf.cm, 30 - 331bf.ft)
b. Fill with fresh engine oil
Capacity
Drain and refill :
W/Oil filter change : 3.31 (3.5U.S.qts, 2.91mp qts)
W/0 Oil filter change : 3.01 (3.17U.S.qts, 2.641mp qts)
c. Install the oil filter cap.
4. Start engine and check for oil leaks.
5. Recheck engine oil level.

SELECTION OF ENGINE OIL
Recommended API classification : SH OR ABOVE

RECOMMENDED SAE VISCOSITY GRADES :
Temperature range
anticipated before Recommended SAE viscosity number
next oil change
·c "F
40 104 20W 15W 10W
10W
-50 -50 -50
-30
20 68 -40 -40 -40
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10 50 5W
-10 14 '1 '1

-40 5W
-15 5 5W. 1
-30
-20. 2
-25 -13
*1 Restricted by driving condition and environment.

*2 Not recommended for sustained high speed vehicle operation
EDA9990B
[gJ) NOTE
For best performance and maximum protection of all
types of operation, select only those lubricants whitch
1. Satist the requirement of the API classification.

2. Have proper SAE grade number for expected am-
bient temperature range.
Lubricants that do not have both an SAE grade num-

ber and API service classification on the container
should not be used.
REMOVAL E2FA6ABA 2) Remove the inner (A) and outer (B) rotors.
1. Drain engine oil.
2. Remove the drive belts.
3. Turn the crankshaft and align the white groove on

the crankshaft pulley with the pointer on the lower
cover.(see page EMA-9)
4. Remove the timing belt.(see page EMA-17)
5. Remove the oil pan and oil screen.(see page EMA-

58,59)
6. Remove the front case.
1) Remove the screws from the pump housing, then

separate the housing and cover (A).
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EDKD203A
DISASSEMBLY EA3DDD34
1. Remove the relief plunger.

Remove the plug(A), spring(B) and relief plunger(C).
EDKD202A
EDKD204A
INSPECTION E7B2B23D 4. Inspect rotor tip clearance.

Using a feeler gauge, measure the tip clearance be-
1. Inspect relief plunger. tween the inner and outer rotor tips.
Coat the valve with engine oil and check that it falls
smoothly into the plunger hole by its own weight. Tip clearance
If it does not, replace the relief plunger. If necessary, 0.025 - 0.069 mm(0.001 0 - 0.0027 in.)
replace the front case.
2. Inspect relief valve spring.

Inspect for distorted or broken relief valve spring.
Standard value
Free height : 46.6mm (1.8346 in.)
Load : 6.1 kg/40.1 mm (13.42 lb/1.579 in.)
3. Inspect rotor side clearance.

Using a feeler gauge and precision straight edge,
measure the clearance between the rotors and
precision straight edge.
Outer 0.04 - 0.085mm
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gear (0.0016 - 0.0033in.)
Side clearance
Inner 0.06 - 0.11 mm
gear (0.0024 - 0.0043in.)
EDKD206A
If the tip clearance is greater than maximum, replace

the rotor as a set.
EDKD205A
If the side clearance is greater than maximum, replace

the rotors as a set. If necessary, replace the front
case.
5. Inspect rotor body clearance. REASSEMBLY ECOD19C1
Using a feeler gauge, measure the clearance between

the outer rotor and body. 1. Install relief plunger.
Install relief plunger(C) and spring(B) into the front
Body clearance : case hole, and install the plug(A).
0.12- 0.18 mm(0.0047- 0.0070 in.)
Tightening torque :
40 - 50Nm (400 - 500kgf.cm, 30 - 371bf.ft)
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EDK0207A
If the body clearance is greater than maximum, re- EDK0204A

place the rotors as a set. If necessary, replace the
front case.
INSTALLATION EDBCAEBA 3. Install the oil pump on the cylinder block.

Place a new front case gasket on the cylinder block.
1. Install oil pump. Apply engine oil to the lip of the oil pump seal. Then,
install the oil pump onto the crankshaft. When the
1) Place the inner and outer rotors into front case pump is in place, clean any excess grease off the
with the marks facing the oil pump cover side. crankshaft and check that the oil seal lip is not dis-
torted.
2) Install the oil pump cover (A) to front case with
the 7 screws.
Tightening torque :
8 - 12Nm (80 - 120kgf.cm, 6 - 91bf.ft)
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EDKD208A
Body length
(A): 30mm (1.18 in)
(B) : 22mm (0.89 in)
(C) : 45mm (1.77 in)
EDKD202A
(D) : 60mm (2.36 in)
2. Check that the oil pump turns freely.
Tightening torque :
20 - 27Nm (200 - 270kg.cm, 14.5 - 19.8 lbf.ft)
4. Apply a light coat of oil to the seal lip.

5. Using the special tooi(09214-32000), install the oil

seal.
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EDKD209A
6. Install the oil screen.(see page EMA-74)
7. Install the oil pan.(see page EMA-75)
@)NOTE
Clean the oil pan gasket mating surfaces.
EMA -96 ENGINE MECHANICAL SYSTE M [1.6 DOHC]
INTAKE AN D EXHAUST
SYSTEM
COMPONENT EOEBCAFD
INTAKE MANIFOLD
15- 20 (150
11 - 15) -200,
intake manifold
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Gasket
18 - 25 (180
13- 28) - 250,
Cylinder head
Intake manifold stay
TORQUE·N
. m (kgf.cm, lbf,ft)
EDKD250A
INTAKE AND EXHAUST SYSTEM EMA -97
EXHAUST MANIFOLD
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Gasket
\
/,pj ~
r
15- 20 (150- 200,
0:) ~c§J
0,
30 - 35 (300 - 350,
22- 26)
11 -15) ~~J /
Heat protector
EDKD251A
MUFFLER
Heat protector
Rear oxygen sensor

50 - 60 (500 - 600, 37 - 44)
30 - 40 {300 - 400, 22 - 30)
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Gasket
Main muffler

ECKE010A

Motor 1.6 DOCH

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Engine Mechanical

Description Specifications Limit

Description Specifications Limit

Description Specifications Limit

Description Specifications Limit

Item Nm kgf.cm lbf.ft

Item Nm kgf.cm lbf.ft

COMPRESSION c. while cranking the engine, measure the compres-

5. Reinstall spark plugs.

6. Install ignition coils. (see EE- ignition)

b. Fully open the throttle.

2. Remove RH front wheel.

4. Remove the alternator belt. 8. Remove the crankshaft pulley (A).

5. Remove the air compressure belt.

6. Remove the power steering belt.

9. Remove the timing belt lower cover.

10. Temperarily loosen tensioner pulley.

1) Rotate crankshaft in regular direction (clock wise

2) Give tension to timing belt rotating tensioner in

3) Tightening tensioner bolt.

4) Then recheck the belt tension.

(across flats) away from the bolt head center.

12. Turn the crankshaft two turns in the operating direc-

camshaft sprocket timing mark.

Symption Suspect area Remedy (See page)

Symption Suspect area Remedy (See page)

Symption Suspect area Remedy (See page)

SPECIAL TOOLS EBA76AE3

Tool (Number and name) Illustration Use

Camshaft oil seal installer Installation of the camshaft oil seal

Valve guide installer Removal and installation of the valve guide

Valve spring compressor Removal and installation of the intake

Tool (Number and name) Illustration Use

Water temperature sensor Removal and installation of the water

Cylinder head cover

TORQUE : Nm (kgf•cm, lbf•ft)

1. Remove the engine cover.

2. Remove RH front wheel.

3. Remove 2bolts (B) and RH side cover (A).

5. Temporarily loosen the water pump pulley bolts.

4. Remove the engine mount bracket.

1) Set the jack to the engine oil pan.

6. Remove alternator belt.(see EE group- alternator)

7. Remove air compressor belt.(see HA group - com-

8. Remove power steering belt.(see ST group - power

9. Remove 4bolts and water pump pulley.

1) Remove the spark plug cable.

2) Remove the accelerator cable (A) from the cylin-

17. Remove the crankshaft sprocket (A).

3) Remove the PCV(Positive Crankcase ventilation)

1. Check the camshaft sprocket, crankshaft sprocket,

2. Inspect the tensioner pulley and the idler pulley for

19. Remove camshaft sprocket.

1) Hold the hexagonal head wrench (A) portion of

1. Check the belt for oil or dust deposits.

2. When the engine is overhauled or belt tension ad-

INSTALLATION E70917F7 2. Install cylinder head cover

1) Temporarily install the camshaft sprocket bolt.

2) Hold the hexagonal head wrench (A) portion of

2) Install the PCV hose (A) and breather hose (B).

3. Install the crankshaft sprocket (A).

EDKD103A 8. Temporarily fasten tensioner pulley to add force at

1) Rotate crankshaft in regular direction (clock wise